acfm overview - tcontrol.ro
TRANSCRIPT
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© 2020 Eddyfi Technologies
ACFM® – OVERVIEW
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Agenda
1. Introduction to ACFM
2. ACFM working principles
3. Tools and applications
4. Subsea specific tools and applications
5. Training
6. Conclusion
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Introduction
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Introduction to ACFM
• Works on ferrous and austenitic materials
although:
• More applications are found with ferrous steels
• Sizing is slightly more accurate sizing in ferrous
materials
• Depth sizing of deep cracks:
• Sizing flaws up to 25mm deep (Weld probe)
• Ideal for large, rough structural welds
• The technique of choice for fatigue crack assessment
• Inspection through thick coatings:
• Sizing possible with up to 4mm thick coatings,
• Detection possible with up to 10mm of LO with reduced
sensitivity
WHAT IS ACFM USED FOR?
‟Detect and size surface breaking cracks in metallic structures through coating”
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Introduction to ACFM
• Efficient and cost effective:
• Minimal surface preparation
• Fast scans / wide coverage / rugged / forgiving
• Versatile
• User-friendly
• Sizing capability = cost effective remedies
• Pedigree / credibility:
• Field proven reliability and high POD
• Approved by regulatory bodies
• Highly compatible, portable and auditable data records
• Comprehensive inspection planning and reporting
WHY ACFM
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Introduction to ACFM
INDUSTRIES AND APPLICATIONS
And more…
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ACFM Origins
• Existing NDT left much to wish for…
• MPI:
• Requires extensive cleaning / coating removal
• No depth sizing / no remaining life assessment
• Not ROV deployable
• ECT:
• Poorly marinized (Back in the days)
• Too sensitive for underwater deployment
• Depth sizing unreliable and limited to about 5mm
• ACPD, a completely forgotten technique today but
back then:
• Was good at sizing BUT required bare metal
• Was difficult to apply underwater
1980’S: FATIGUE CRACKING ISSUES IN SUBSEA O&G STRUCTURES
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ACFM Origins
• University College of London:
• Original technological development
• First instruments/probes designed and built
• Development of a mathematical model for sizing
• Substantial investments in validation:
• Funded by JIP – Shell, BP, CP, BG
• UW blind trials to compare ACFM, MPI and EC
• Full POD using several realistic defects and geometries
• POS data (Below) still used for normalizing ACFM sizing
• Led to extensive ICON trials offshore
EARLY 1990’S: DEVELOPMENT OF THE ACFM SOLUTIONElectric Field
Magnetic Field
0
5
10
15
20
25
0 5 10 15 20 25
AC
FM
Pre
dic
ted
de
pth
, m
m
Characterised depth, mm
Depth from ACPD/TOFDbefore coating
Depth from ACPD/TOFD - nocoating
Depth measured aftersectioning
Equality
+15%
-15%
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ACFM working principles
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Key Elements
Uniform
FieldsButterfly Sizing
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ACFM working principles
• The field coil:
• Sits high in the probe (Blue)
• Is driven with a constant alternating current source
• Generates a uniform field in the target
• Cracks disturb the flow of fields in the target:
• Some are forced under it (Green)
• Some flow around its edges (Red)
• Small coils in closer proximity to the target senses the
disturbances:
• The Bx coil (Green) is sensitive to fields diving under the crack
• The Bz coil (Red) is sensitive to fields flowing around the crack edges
UNIFORM FIELDS
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ACFM working principles
• The Bx signal:
• Generally goes down when going over a crack
• Amplitude is related to the crack depth
• Is used to discriminate between crack orientations
• The Bz signal:
• Generates a trough near one crack end and a peak near the other end
• Is related to the crack length
• The butterfly:
• Is a combination of the Bx and Bz signals
• Provides simple and clear information
• Enables efficient and reliably analysis with easy to learn rules
• Can be used to discriminate between cracks and other features
BUTTERFLY
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• No onsite calibration: the sizing capabilities are self
contained in the system
• Assisted analysis:
• Automatic gating captures the essential parameters
of the signals
• The parameters are processed by software
• Defect sizing is based on a mathematical model of
the electromagnetic field – crack interaction
• Comprehensive reporting:
• Automatically generated reports
• Includes signal / C-scan screenshots
• Includes detailed flaw position and measurements
• Provides fully auditable and transparent inspection
records
• General detection and sizing figures:
SIZING AND
REPORTING
ACFM working
principles
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• Hi field coil, uniform fields and constant current means:
• Less probe induced variables
• Disturbances largely dominated by cracks, much less by LO
variations or weld roughness
• Wide coverage makes it forgiving to inspectors
• … In short: Improved POD and reduced false calls
• The combination of sensor coils provide rich and clear
information:
• Enables further discrimination of flaws vs noise
• Enables accurate length and depth sizing
• Unique sizing capabilities:
• Sizing flaws up to 25mm deep (Weld probe)
• Sizing possible with up to 4mm thick coatings,
• Detection possible with up to 10mm of LO with reduced
sensitivity
WHAT MAKES IT SO
SPECIAL
ACFM working
principles
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Tools and applications
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ACFM approvals
Recommends the control of welds using the
Alternating Current Field Measurement technique
or A.C.F.M.
Standard Practice for Examination of Welds using
the ACFM Technique (E2261-03), latest revision
E2261-12
Standard Practice for Examination of Drill String
Threads using the ACFM Technique (E2928-13)
ASME V Article 15: ACFM Technique, 2006
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ACFM instruments
Amigo™ 2
Pace®
• Powerful, fast
• High quality multichannel data
• Supports multiple applications
• High probe compatibility: legacy,
Sensu, Sensu 2, high speed
arrays and application specific
• Modern, state of the art
hardware/software
• Ideal for rope access
• Basic weld inspection
• Supports 5/50KHz Sensu pencil
probes:
• Straight
• Right angle
• Transverse
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GENERIC SENSU 2
PROBES
TOOLS
• All Sensu 2 probes feature:
• IP65 rating
• Fast acquisition, pristine data quality, high SNR
• Connectorized to 5, 20 or 50m cables
• Config/calibration stored in probe memory
• Convenient buttons and LED indicators
• The new Sensu 2 flagship probes: high speed arrays
• Integrated encoder and coverage up to 90mm
• Dual fields: Bi-axial crack detection and sizing in one pass
• Spring loaded micro-elements. Typical crack detection is
5mm x 0.5mm and above, crack depth sizing up to 20mm
• Weld probe:
• Features stabilizers and a wider field
• The wider field enables depth sizing as deep as 25mm
• Covers 15mm in one pass
• Pencil probes:
• Versatile and ideal for tight access
• 3 orientations available
• Covers 15mm in one pass
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SOFTWARE
PACKAGES
TOOLS
Pace Amigo 2
Embedded software for portable units✓ Acquisition
✓ Analysis
✓ Report generation and export (Word, PDF, Excel)
Included in Pace unit
ASSIST-GO-SS1
ASSIST-GO-SS5
Reader/viewer for desktopSame interface and functionalities as GO
✓ Data readback
✓ Analysis
✓ Report generation and export (Word, PDF, Excel)
Not supported for PaceASSIST-CP-SS1
ASSIST-CP-SS5
Acquisition and analysis software for
desktop ✓ Acquisition / remote control capabilities (RDAU)
✓ Inspection planning, analysis and reporting functionalities
✓ Report generation and export (Word, PDF, Excel)
Not supported for Pace
ASSIST-PRO-SS1
ASSIST-PRO-SS5*ASSIST-PRO-DIVER also compatible but more
expensive so only relevant if the customer owns U41
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ACFM applications
PROCESS PLANT & REFINERY INSPECTION
Crack detection and sizing through coatings on:
• Pipework
• Pressure vessels
• Attachments
• Nozzles
• And much more…
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STORAGE TANK
WELD INSPECTION
ACFM
applications
• Crack detection and sizing with
minimal cleaning
• Wide adoption in France
(COFREND)
• Annular welds with weld probe
• Fast array probe scans:
• Generic welds in one pass
• Lap joints up to 10mm high
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• High temperature components requiring in-
service inspection:
• Pre- and post-inspection of hot tapped
weldolets and split tees
• Pressure vessels
• Steam pipes, etc.
• Conventional methods (MT/PT) are limited:
• Typical max. temp: 50-60°C
• Specialist variants can go up to 200-215°C but
come with compromised sensitivity
• Standard ACFM probes:
• 80°C in continuous
• Contact time @ 150°C: 50 seconds
• Contact time @ 200°C: 10 seconds
• Special air cooled ACFM probes:
• Performance demonstrated at 300°C
• Lab tested up to 400°C
HIGH TEMPERATURE
COMPONENTS
ACFM
applications
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CIVIL STRUCTURES
ACFM
applications
Amusement parks Cranes
Bridges Building frames
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ACFM applications
DRILL STRING THREAD INSPECTION
• Drill string threaded connections are critical to drilling
operations:
• Weakest link of the bottom hole assembly (BHA)
• Sustain heavy stresses and are prone to fatigue cracking
• Lost BHA due to thread twist-offs are very expensive
(~400K USD)
• Traditional inspection methods (MT/PT) leave much
to wish for:
• Requires careful cleaning, slow inspection process
• Difficult geometry and bad visibility compromises detection
• Dirty process: Not environmentally friendly
• No crack depth sizing/no cost effective remedy decisions
• ACFM offers a reliable and cost effective alternative!
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THE ACFM UNIVERSAL THREAD
PROBE (UTP)
• One probe for pin/box
• 3D printed shoes are used to mate with
various diameters/thread pitch
• Box ID supported:
–From 3.5’’ IF, 3.5’’ Reg., NC38 and up
• Supported thread pitch:
–As small as 4 TPI
–Down to 5 TPI with slight sensitivity loss
• String on rollers for high productivity
• Fast, reliable, field proven
ACFM applications
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• When used on drill string threads, MT POD is
not as good as usually expected
• Comparative trials were conducted…
• Halliburton tried over 140 threads:
• ACFM identified 23 defects with depth information
• 9 could be reworked and returned to service
• 2 were missed with MT
• Shell tried over 20 drill collars:
• 2 discrepancies between ACFM and MT were re-
inspected and sectioned…
• MT missed a 0.016’’ deep crack found with ACFM
• MT produced one false call
• Experience has shown that in general, ACFM
finds genuine flaws on 1-2% of threads
previously inspected and missed by MT
• ACFM is approved by NS2 and ASTM
international for this application
PROVEN
SUPERIORITY FOR
DRILL STRING
THREAD INSPECTION
ACFM
applications
X125
X50* POD curve source: Dale B A and Moyer M C. "Sensitivity and Reliability of Commercial Drillstring
Inspection Services". 7th Offshore South East Asia Conference, Singapore, February 1988.
MT missed
MT overcall
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ACFM applications
RAILWAY RELATED APPLICATIONS
• ACFM a railway proven inspection technique for ~20 years
• Axle and wheelset inspection:
• Fatigue cracking detection and sizing
• An independent blind trial on 15 failed axles was conducted
• ACFM proved to be superior to ECT and far superior to MT/MPI
• Various welds inspection:
• Tank car welds
• Bogie frame welds
• Attachment welds
• Rail inspection:
• Fast and reliable detection of Rolling Contact Fatigue (RCF) cracks
• ACFM has been tested, field proven and approved by UK railways, Corus Rail Technologies (on behalf of Network Rail), Balfour Beatty Rail Technologies and York EMC Services, UK.
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ACFM applications
AXLE INSPECTION DETAILS
• ACFM was proven during an
independent blind trial*:
• 15 axles with known failures
• ACFM has the highest POD and
lowest false calls
• ACFM adds the depth sizing
capability on top of detection
• Perfect match for the Amigo 2 /
Sensu 2 array probes
Experimental
POD
Potential
POD
Axles flagged
as ‘’Failed’’
MT/MPI 44% 59% 5
ECT 80% 85% 11
ACFM 84% 95% 15
* M Pollard and A Lear, ‘Report 11363/03 – Evaluation of Electromagnetic Non-destructive Testing Techniques – Executive Summary and Recommended
Way Forward’, The Engineering Link, 2000.
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ACFM topside applications
RAIL INSPECTION DETAILS
• ACFM proven during an independent blind trial:
• Corus Rail Technologies on behalf of Network Rail
• Tested 72 rail sections with RCF cracking, proofed with destructive testing
• “…the capability of detection of the ACFM® system has been found
to be close to 100%.”
• Other successful trials by UK railways, Balfour Beatty Rail Technologies
and York EMC Services, UK.
• Semi-autonomous deployment or “Walking stick”
• Rich data:
• High resolution
• Fast collection: 20Km/h+
• Clear C-scan representations
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• ACFM is field proven and ideal for mining
applications:
• Difficult environments, dirty/greasy/worn
components
• Large defects in big components
• Frequent fatigue cracking requiring depth
sizing
• Typical applications:
• Welds in large structural components
• Gear teeth inspection (ACFM specified by
ASTM E2905)
IN THE MINING
INDUSTRY
ACFM
applications
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Subsea specific tools and applications
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ACFM subsea
APPROVALS
Non-Destructive Testing of Hull Welds, February 2014. Section 6, ACFM Technique
Classification Note No. 7, March 2012. Section 2.1, Detection of surface breaking cracks
Accepted for in-service examination of structural welds
TSC is also an LR certified ACFM Inspection Services Provider
BS EN ISO 19902: Petroleum and natural gas industries. Fixed steel offshore structures
Approved technique surface breaking crack detection
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U41: for the deep
• Ideal for diver inspection down to 300m
• Connects with up 3x Sensu 2 UW probes simultaneously,
avoiding frequent returns to the surface
• Connects to the topside unit with up to 3x 150m umbilical
• State-of-the-art electronics: fast scans, high data quality
• Array probe support:
• Diver mini-array probe with 36mm wide coverage
• ROV full-array probes
• Reduced number of scans
• Faster recognition and characterization of defects
• For deeper ROV applications: See TSC Subsea
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Amigo™ 2: for shallower waters
• Topside deployment through 50m underwater
cables
• Versatile: also supports multiple topside
applications
• State-of-the-art electronics: fast scans, high
data quality
• Supports the same probe heads as the U41
but connected through 50m cables instead
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SOFTWARE
PACKAGES
ACFM UNDER
WATER
U41
Analysis software for desktop ✓ Acquisition / remote control capabilities (RDAU)
✓ Advanced analysis and reporting functionalities
✓ Report generation and export (Word, PDF, Excel)
ASSIST-PRO-DIVER-SS1
ASSIST-PRO-DIVER-SS5
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GENERIC SENSU 2
UNDERWATER
PROBES
SUBSEA
TOOLS
• All Sensu 2 underwater probes feature:
• IP68 rating down to 300m underwater
• Fast acquisition, pristine data quality, high SNR
• Cable options: 5m for U41, 50m for Amigo 2
• Config/calibration stored in probe memory
• Diver mini-array:
• Designed to make divers’ work easier and more reliable
• Features stabilizers and a 36mm wide coverage
• Weld probe:
• Features stabilizers and a wider field
• The wider field enables depth sizing as deep as 25mm
• Covers 15mm in one pass
• Tight access probe:
• A weld probe designed for hard-to-reach areas
• Ground weld probe:
• Features a long slender nose to fit into weld repair grinds
• Enables monitoring throughout the repair process
• Pencil probes:
• Versatile and ideal for tight access
• 3 orientations available all with 15mm wide coverage
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ACFM UNDERWATER
COMMON
APPLICATIONS
• Jackets:• Structural node welds
• Attachment welds: looking for cracks
when there is a flooded member
• Jack-ups:• Leg node welds
• Spudcan welds
• Hull inspection
• Semi-subs:• Leg welds
• Hull welds (UWILD inspections)
• FPSOs: hull inspections
• Pipeline damage investigation (anchor,
drag, etc.)
• Mooring systems including chains
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ACFM Training
• Eddyfi Academy
• Online product training
• SNT-TC-1A compliant ACFM level 2 by blended learning
• Operator Certification available through SNT-TC-
1A, PCN, and CSWIP Schemes
• PCN through Lavenders International (UK,
Houston, and others)
• CSWIP through TWI (UK and others)
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In Conclusion
• ACFM is a mature and certified technique
• Crack detection + length and depth sizing
• Cleaning not required
• Works on ferromagnetic and austenitic
• Auditable: all data is stored
• Rugged, forgiving and perfect for robotic integration
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